Bifacial solar cell module with backside reflector

ABSTRACT

A bifacial solar cell module includes solar cells that are protected by front side packaging components and backside packaging components. The front side packaging components include a transparent top cover on a front portion of the solar cell module. The backside packaging components have a transparent portion that allows light coming from a back portion of the solar cell module to reach the solar cells, and a reflective portion that reflects light coming from the front portion of the solar cell module. The transparent and reflective portions may be integrated with a backsheet, e.g., by printing colored pigments on the backsheet. The reflective portion may also be on a reflective component that is separate from the backsheet. In that case, the reflective component may be placed over a clear backsheet before or after packaging.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/660,292, filed on Oct. 25, 2012, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

Embodiments of the subject matter described herein relate generally tosolar cells. More particularly, embodiments of the subject matter relateto solar cell modules.

BACKGROUND

Solar cells are well known devices for converting solar radiation toelectrical energy. A solar cell has a front side that faces the sunduring normal operation to collect solar radiation and a backsideopposite the front side. Solar radiation impinging on the solar cellcreates electrons and holes that migrate to diffusion regions, therebycreating voltage differentials between the diffusion regions. Metalcontacts are formed to corresponding diffusion regions to allow anexternal electrical circuit, e.g., a load, to be connected to and bepowered by the solar cell.

Solar cells may be serially connected and packaged together to form asolar cell module. The packaging provides environmental protection forthe solar cells, and may include a top cover on the front side, anencapsulant that encapsulates the solar cells, and a backsheet thatprovides insulation on the backside. Embodiments of the presentinvention pertain to a backsheet and other backside packaging componentsthat allow for increased solar radiation collection.

BRIEF SUMMARY

In one embodiment, a bifacial solar cell module includes solar cellsthat are protected by front side packaging components and backsidepackaging components. The front side packaging components include atransparent top cover on a front portion of the solar cell module. Thebackside packaging components have a transparent portion that allowslight coming from a back portion of the solar cell module to reach thesolar cells, and a reflective portion that reflects light coming fromthe front portion of the solar cell module. The transparent andreflective portions may be integrated with a backsheet, e.g., byprinting colored pigments on the backsheet. The reflective portion mayalso be on a reflective component that is separate from the backsheet.In that case, the reflective component may be placed over a clearbacksheet before or after packaging.

These and other features of the present invention will be readilyapparent to persons of ordinary skill in the art upon reading theentirety of this disclosure, which includes the accompanying drawingsand claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the subject matter may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures. The drawings are notto scale.

FIG. 1 shows a bifacial solar cell module in accordance with anembodiment of the present invention.

FIGS. 2-4 are cross-sectional views schematically illustrating a methodfor making a bifacial solar cell module in accordance with an embodimentof the present invention.

FIG. 5 schematically shows an arrangement of solar cells in a bifacialsolar cell module in accordance with an embodiment of the presentinvention.

FIG. 6 schematically shows a cross section of a bifacial solar cellmodule in accordance with an embodiment of the present invention.

FIG. 7 schematically shows another cross section of a bifacial solarcell module in accordance with an embodiment of the present invention.

FIG. 8 shows a backsheet in accordance with an embodiment of the presentinvention.

FIG. 9 schematically shows a backsheet that is overlaid on solar cellson a back portion of a bifacial solar cell module in accordance with anembodiment of the present invention.

FIG. 10 schematically shows a backsheet in accordance with anotherembodiment of the present invention.

FIG. 11 schematically shows a backsheet that is overlaid on solar cellson a back portion of a bifacial solar cell module in accordance with anembodiment of the present invention.

FIG. 12 schematically shows a reflective component that is separate froma backsheet on a back portion of a bifacial solar cell module inaccordance with an embodiment of the present invention.

FIG. 13 schematically shows a reflective component that is separate froma backsheet on a back portion of a bifacial solar cell module inaccordance with another embodiment of the present invention.

DETAILED DESCRIPTION

In the present disclosure, numerous specific details are provided, suchas examples of components, materials, and methods, to provide a thoroughunderstanding of embodiments of the invention. Persons of ordinary skillin the art will recognize, however, that the invention can be practicedwithout one or more of the specific details. In other instances,well-known details are not shown or described to avoid obscuring aspectsof the invention.

FIG. 1 shows a bifacial solar cell module 100 in accordance with anembodiment of the present invention. The bifacial solar cell module 100is a so-called “terrestrial solar cell module” in that it is designedfor use in stationary applications, such as on rooftops or byphotovoltaic power plants. In the example of FIG. 1, the bifacial solarcell module 100 includes an array of interconnected solar cells 101.Only some of the solar cells 101 are labeled in FIG. 1 for clarity ofillustration. In the example of FIG. 1, the solar cells 101 comprisebackside contact solar cells. In a backside contact solar cell, alldiffusion regions and metal contacts coupled to the diffusion regionsare formed on the backside of the solar cell. That is, both the P-typeand N-type diffusion regions and metal contacts coupled to them are onthe backside of the solar cell. Embodiments of the present invention areespecially advantageous when employed with backside contact solar cells,as they allow for collection of solar radiation from the backside thatwould otherwise be wasted. In other embodiments, the solar cells 101 mayalso be front side contact solar cells or other types of solar cells.

Visible in FIG. 1 are the front sides of the solar cells 101. The frontsides of the solar cells 101 are also referred to as the “sun side”because they face towards the sun during normal operation. The backsidesof the solar cells 101 are opposite the front sides. A frame 102provides mechanical support for the solar cells 101. The front portion103 of the bifacial solar cell module 100 is on the same side as thefront sides of the solar cells 101 and is visible in FIG. 1. The backportion 104 of the bifacial solar cell module 100 is under the frontportion 103. The back portion 104 of the bifacial solar cell module 100is on the same side as the backsides of the solar cells 101. Thebifacial solar cell module 100 is “bifacial” in that it allows forcollection of solar radiation coming from the front portion 103 and theback portion 104.

FIGS. 2-4 are cross-sectional views schematically illustrating a methodof making a bifacial solar cell module 100 in accordance with anembodiment of the present invention.

FIG. 2 is an exploded view showing the components of the bifacial solarcell module 100 in accordance with an embodiment of the presentinvention. The bifacial solar cell module 100 may comprise a transparenttop cover 251, sheets of encapsulant 252, the solar cells 101,interconnects 254, and a backsheet 253. The backsheet 253 may be anysingle layer or multiple layers of materials that provide environmentalprotection to other components of the solar cell module 100. Forexample, flouropolymer, polyvinylidene fluoride,polytetrafluoroethylene, polypropylene, polyphenylene sulfide,polyester, polycarbonate, or polyphenylene oxide may be used as a singlelayer or as part of multiple layers of backsheet. The encapsulant 252 onthe front portion 103 is labeled as “252-1” and the encapsulant 252 onthe back portion 104 is labeled as “252-2.” The transparent top cover251 and the front side encapsulant 252-1 serve as front side packagingcomponents, and the encapsulant 252-2 and the backsheet 253 serve asbackside packaging components. In the example of FIG. 2, the transparenttop cover 251 is the outermost front side packaging component and thebacksheet 253 is the outermost backside packaging component.

The transparent top cover 251 and the encapsulant 252 comprise opticallytransparent materials. The transparent top cover 251, which is thetopmost layer on the front portion 103, protects the solar cells 101from the environment. The bifacial solar cell module 100 is installed inthe field such that the transparent top cover 251 faces the sun duringnormal operation. The front sides of the solar cells 101 face towardsthe sun by way of the transparent top cover 101. In the example of FIG.2, the transparent top cover 201 comprises glass (e.g., 3.2 mm thick,soda lime glass).

The encapsulant 252 is configured to protectively encapsulate the solarcells 101. In one embodiment, the encapsulant 252 comprises a highresistivity material configured to prevent solar cell polarization bypreventing electrical charge from leaking from the front sides of thesolar cells 101 to other portions of the bifacial solar cell module 100.In one embodiment, the encapsulant 252 presents a high resistance pathto electrical charges to prevent charge leakage from the front sides ofthe solar cells 101 to the frame 102 or other portions of the bifacialsolar cell module 100 by way of the transparent top cover 251. In theexample of FIG. 2, sheets of high resistivity encapsulant 252 are placedon the front sides and backsides of the solar cells 101. In someembodiments, a sheet of high resistivity encapsulant 252 is only on thefront sides of the solar cells 101. In those embodiments, the sheet ofencapsulant on the backsides of the solar cells 101 is not a highresistivity encapsulant, such as poly-ethyl-vinyl acetate (“EVA”), forexample.

The interconnects 254 may comprise a metal for electricallyinterconnecting the solar cells 101. In the example of FIG. 2, the solarcells 101 comprise serially-connected backside contact solar cells, andthe interconnects 254 electrically connect to corresponding P-type andN-type diffusion regions on the backsides of the solar cells 101. In oneembodiment, interconnect shields (e.g., see FIG. 7, shield 256) areplaced on the interconnects 254 on the sun side to visually block theinterconnects 254 when viewed from the front portion 103 and/or toprovide a reflective surface to scatter, i.e., reflect at multipleangles, light coming from the front portion 103. Interconnect shieldsfor solar cell applications are also disclosed in commonly-assigned U.S.Pat. No. 7,390,961, which is incorporated herein by reference in itsentirety.

The backsides of the solar cells 101 face the backsheet 253. In oneembodiment, the backsheet 253 comprises Tedlar/Polyester/EVA (“TPE”).The backsheet 253 may also comprise Tedlar/Polyester/Tedlar (“TPT”) or amulti-layer backsheet comprising a fluoropolymer, to name some examples.The backsheet 253 is on the back portion 104. As will be more apparentbelow, the backsheet 253 may comprise a backsheet printed with areflective surface to reflect light that would otherwise escape towardsthe back portion 104.

In one embodiment, the transparent top cover 251, the encapsulant 252-1on the front side, the solar cells 101 electrically connected by theinterconnects 254, the encapsulant 252-2 on the backside, and thebacksheet 253 are formed together to create a protective package. Thisis illustrated in FIG. 3, where the aforementioned components are formedtogether in a stacking order as shown in FIG. 2. More particularly, thesolar cells 101 are placed between the encapsulants 252-1 and 252-2, thebacksheet 253 is placed under the encapsulant 252-2, and the transparenttop cover 251 is placed over the encapsulant 252-1. The just mentionedcomponents are then pressed and heated together by vacuum lamination,for example. The lamination process melts together the sheet ofencapsulant 252-1 and the sheet of encapsulant 252-2 to encapsulate thesolar cells 101. In FIG. 3, the encapsulant 252-1 and the encapsulant252-2 are simply labeled as “252” to indicate that that they have beenmelted together.

FIG. 4 shows the protective package of FIG. 3 mounted on the frame 102.Being encapsulated in the encapsulant 252, the solar cells 101 areelectrically isolated from the frame 102.

FIG. 5 schematically shows an arrangement of the solar cells 101 in thebifacial solar cell module 100 in accordance with an embodiment of thepresent invention. Only some of the solar cells 101 are shown forclarity of illustration. In the example of FIG. 5, the solar cells 101are arranged in rectangular fashion in rows and columns. The solar cells101 may be electrically connected in series by the interconnects 254along a column. A column of solar cells 101 may be serially connected toan adjacent column of solar cells 101 at the ends of the columns (notshown). Of course, the solar cells 101 may also be interconnected byrow.

Each solar cell 101 may be spaced apart from an adjacent solar cell 101by about 2 mm on each side. As will be more apparent below, the spacebetween solar cells 101 where there is no interconnect 254 may becovered by a reflective surface that is on the backsheet 253 (or otherbackside packaging component). For example, the space generally boundedby dotted lines 258 may have a corresponding reflective portion on thebacksheet 253. The reflective portion may cover the area between sidesof adjacent solar cells 101 (e.g., see sides 259) and the “diamond” areaformed by four adjacent solar cells 101 (e.g., see diamond area 260).

FIG. 6 schematically shows a cross section of the bifacial solar cellmodule 100 in accordance with an embodiment of the present invention.FIG. 6 is taken from along a row of solar cells 101, where the sides arenot connected by interconnects 254 (e.g., see section A-A of FIG. 5). Inthe example of FIG. 6, the solar cells 101 along a column are connectedby interconnects 254 going into the page of the figure.

In one embodiment, the backsheet 253 has a reflective portion 253-1 andtransparent portions 253-2. The reflective portion 253-1 provides areflective surface for scattering light and the transparent portions253-2 are clear to allow light to readily pass through. In operation,light coming from the front portion 103 may pass through the transparenttop cover 251, the encapsulant 252, and onto the front sides of thesolar cells 101 (see arrows 301). Light coming from the front portion103 but passes between the solar cells 101 is reflected by thereflective portion 253-1 (see arrow 302) towards the front portion 103.Some of the reflected light, which would otherwise be wasted, eventuallyenters the front sides of the solar cells 101 (see arrow 302). Lightcoming from the back portion 104 enters through the transparent portions253-2 (see arrows 303) and may eventually enter the backsides or frontsides of the solar cells 101. The reflective/transparent design of thebacksheet 253, or other backside packaging component employing suchdesign, thus allows for increased solar radiation collection.

In one embodiment, the reflective portion 253-1 has an averagereflectance of at least 30%, preferably 50%, more preferably 70% in allwavelengths between 400 nm and 1200 nm. For example, the reflectiveportion 253-1 may comprise white pigments (e.g., titanium dioxide,barium sulfate, and mixtures thereof). The reflective portion 253-1 mayalso comprise other materials, such as ultra violet (UV) stabilizersand/or heat stabilizers. Other suitable colors for the reflectiveportion 253-1 may include black, red, green, or other color for cosmeticpurpose. In general, the material and color of the reflective portion253-1 may be selected for optimum light scattering for a particularsolar cell module. For example, even though silver may be an excellentreflector, a reflective portion 253-1 made of silver may not scatterenough light to be efficient because most of the reflected light maysimply reflect straight out of the solar cell module. In that case, whenusing silver or other highly reflective material, the reflective portion253-1 may be textured for optimum light scattering.

Reflective materials may be printed directly on a clear, i.e.,completely transparent, backsheet 253. The printed portion forms thereflective portion 253-1 and portions where the reflective material isnot printed form the transparent portions 253-2.

FIG. 7 schematically shows another cross section of the bifacial solarcell module 100 in accordance with an embodiment of the presentinvention. FIG. 7 is taken from along a column of solar cells 101 wherethere are interconnects 254 (e.g., see section B-B of FIG. 5). In theexample of FIG. 7, a reflective interconnect shield 256 is placedtowards the sun side to reflect light that would otherwise hit the frontside of a corresponding interconnect 254. The reflective interconnectshield 256 may have the same properties and characteristics as thereflective portion 253-1 of the backsheet 253. In operation, lightcoming from the front portion 103 passes through the transparent topcover 251, the encapsulant 252, and onto the front sides of the solarcells 101 (see arrows 311). Light coming from the front portion 103 butpasses between solar cells 101 is reflected by the interconnect shield304 (see arrow 312) towards the front portion 103. Some of the reflectedlight, which would otherwise be wasted, eventually enters the frontsides of the solar cells 101 (see arrow 312). Light coming from the backportion 104 enters through the transparent portions 253-2 (see arrows313) and may eventually enter the backsides or front sides of the solarcells 101.

FIG. 8 shows the backsheet 253 in accordance with an embodiment of thepresent invention. In the example of FIG. 8, the reflective portion253-1 is configured to cover space between solar cells 101 along onlyone dimension (e.g., between columns of solar cells 101) where there isno interconnect 254 between the solar cells 101. For example, thereflective portion 253-1 may be configured to cover from 80% to 300%(e.g., for alignment tolerance in manufacturing) of the space betweensides of the solar cells 101, and diamond areas formed by four adjacentsolar cells 101. The transparent portions 253-2 allow light to freelypass through the backsheet 253 and onto the solar cells 101. Thetransparent portions 253-2 may have an average optical transmission ofat least 50%, preferably 70%, more preferably 90% in all wavelengthsbetween 400 nm and 1200 nm.

FIG. 9 schematically illustrates the backsheet 253 overlaid on the solarcells 101 on the back portion 104 of the bifacial solar cell module 100in accordance with an embodiment of the present invention. The exampleof FIG. 9 shows the bifacial solar cell module 100 as seen from the backportion 104. The backsheet 253 is placed over the solar cells 101 (onlysome are labeled in FIG. 9) and are formed together by, for example,vacuum lamination. Some of the interconnects 254 connecting the solarcells 101 are labeled in FIG. 9 for reference purposes. The backsides ofthe solar cells 101 show through the transparent portions 253-2, whilethe space between adjacent columns of solar cells 101 are covered by thereflective portion 253-1.

In other embodiments, the reflective portion 253-1 may also cover thespace between two dimensions, such as between columns and rows of solarcells 101. An example of this embodiment is shown in the backsheet 253Aof FIG. 10, where the reflective portion 253-1 covers the space betweensolar cells 101 in both the vertical and horizontal dimensions. Thereflective portion 253-1 surrounds each solar cell 101 in thisembodiment. As before, the transparent portions 253-2 expose thebacksides of the solar cells 101, allowing light coming from the backportion 104 to pass through. The reflective portion 253-1 also coversthe space between the frame and adjacent solar cells 101 along twodimensions.

FIG. 11 schematically illustrates the backsheet 253A of FIG. 10 overlaidon the solar cells 101 on the back portion 104 of the bifacial solarcell module 100 in accordance with an embodiment of the presentinvention. The example of FIG. 11 shows the bifacial solar cell module100 as seen from the back portion 104. The backsheet 253A is placed overthe solar cells 101 (only some are labeled in FIG. 11) and are formedtogether by, for example, vacuum lamination. The backsides of the solarcells 101 show through the transparent portions 253-2, while the spacebetween adjacent solar cells 101 and the space between solar cells 101and the frame are covered by the reflective portion 253-1.

Integrating the reflective portion 253-1 with the backsheet 253simplifies the manufacture of the bifacial solar cell module 100; thebacksheet 253 already comes with the reflective and transparentportions. However, it is not necessary to integrate the reflectiveportion 253-1 with the backsheet 253. For example, a clear backsheetwith no reflective portion may also be used. In that case, aftercreating the protective package, a separate white (or other colored)tape or other reflective component may be attached on the clearbacksheet. An example of this embodiment is schematically illustrated inFIG. 12, where the transparent cover 251, the solar cells 101encapsulated in the encapsulant 252, and the backsheet 371 are packagedtogether by, for example, vacuum lamination. The backsheet 371 comprisesa completely clear backsheet that exposes the backsides of the solarcells 101 to receive light coming from the back portion of the bifacialsolar cell module 100. A reflective component 372 with characteristicsand pattern similar to the reflective portion 253-1 may be applied onthe backsheet 371 after lamination. For example, the reflectivecomponent 372 may comprise white colored tape that is attached to thebacksheet 371.

The reflective component 372 may also be placed between the clearbacksheet 372 and the encapsulant 252-2 before packaging as shown inFIG. 13. The transparent cover 251, the encapsulants 252-1 and 252-2,the solar cells 101, the reflective material 372, and the backsheet 371are thereafter formed together to create the protective package, e.g.,by vacuum lamination.

Bifacial solar cell modules and methods for manufacturing same have beendisclosed. While specific embodiments of the present invention have beenprovided, it is to be understood that these embodiments are forillustration purposes and not limiting. Many additional embodiments willbe apparent to persons of ordinary skill in the art reading thisdisclosure.

What is claimed is:
 1. A bifacial solar cell module comprising: aplurality of solar cells; an encapsulant that encapsulates the pluralityof solar cells; a backsheet on a back portion of the bifacial solar cellmodule; and a reflective component having a continuous reflectiveportion and a plurality of transparent portions that are coplanar withthe continuous reflective portion and within spaces defined by thereflective portion.
 2. The bifacial solar cell module of claim 1,wherein the reflective component is between the encapsulant and thebacksheet.
 3. The bifacial solar cell module of claim 1, wherein thebacksheet is between the reflective component and the encapsulant. 4.The bifacial solar cell module of claim 1, wherein the backsheet isattached to the backsheet on an outside portion of the backsheet.
 5. Thebifacial solar cell module of claim 1, wherein the backsheet is a clearbacksheet.
 6. The bifacial solar cell module of claim 1, wherein thesolar cells are arranged in an array, and the continuous reflectiveportion covers rows and columns of the array.
 7. The bifacial solar cellmodule of claim 1, wherein the solar cells are arranged in an array, andthe continuous reflective portion covers one dimension of the array. 8.The bifacial solar cell module of claim 1, further comprising: atransparent top cover on a front portion of the bifacial solar cellmodule.
 9. The bifacial solar cell module of claim 8, further comprisinga frame that provides mechanical support to the transparent top cover,the encapsulant, the reflective component, and the backsheet.
 10. Thebifacial solar cell module of claim 1, wherein the solar cells comprisebackside contact solar cells.
 11. A bifacial solar cell module,comprising: a plurality of solar cells that are arranged in an array; anencapsulant that encapsulates the solar cells; a clear backsheet; and areflective component comprising a continuous reflective portion andtransparent portions that are coplanar with and within spaces defined bythe continuous reflective portion, the continuous reflective portioncovering a first dimension of the array.
 12. The bifacial solar cellmodule of claim 11, wherein the first dimension is a row of the arrayand the continuous reflective portion further covers a column of thearray.
 13. The bifacial solar cell module of claim 11, wherein thereflective component is between the clear backsheet and the encapsulant.14. The bifacial solar cell module of claim 11, wherein the clearbacksheet is between the encapsulant and the reflective component. 15.The bifacial solar cell module of claim 11, further comprising atransparent top cover on a front portion of the bifacial solar cellmodule.
 16. The bifacial solar cell module of claim 15, furthercomprising a frame that supports the transparent top cover, theencapsulant, the reflective component, and the clear backsheet.
 17. Abifacial solar cell module comprising: a transparent top cover on afront portion of the bifacial solar cell module; a backsheet on a backportion of the bifacial solar cell module; an encapsulant thatencapsulates a plurality of solar cells, the encapsulant being disposedbetween the transparent top cover and the backsheet; a reflectivecomponent comprising a continuous reflective portion and a plurality oftransparent portions, the plurality of transparent portions beingcoplanar with and within spaces defined by the continuous reflectiveportion; and a frame that mechanically supports the transparent topcover, the backsheet, the encapsulant, and the reflective component. 18.The bifacial solar cell module of claim 17, wherein the backsheet is aclear backsheet and the reflective component is between the encapsulantand the backsheet.
 19. The bifacial solar cell module of claim 17,wherein the backsheet is a clear backsheet and the reflective componentis on an outside portion of the backsheet.
 20. The bifacial solar cellmodule of claim 17, wherein the solar cells comprise backside contactsolar cells.